A method of making a projectile apparatus is provided that includes making one or components of the apparatus using an additive manufacture technique such as 3-D printing or laser-aided additive manufacture. The projectile apparatus can have a projectile, a propellant, and one or more optional components such as a wading, a sabot, and an intermediary device. The projectile can be fired through a barrel having a smooth bore. Additive manufacture methods can be used that involve forming components from superalloys having nanoparticles incorporated therein. The projectile apparatus can convert gas pressure or gas velocity into a high rate of projectile spin. The projectile has long-range accuracy due to a high or sustainable velocity and high rate of spin.

A rocket motor for a gun-fired projectile is configured stiffen the burnable propellant in the rocket motor during burning and/or protect the rocket motor from the pressure that occurs during firing of the projectile from the gun. The rocket motor may include a rigid structure that is integrated into the burnable propellant grain to stabilize the burnable propellant grain during burning of the burnable propellant grain. The rigid structure has a matrix or truss-like shape that extends into the depth of the burnable propellant grain. The rocket motor may include a baffled end cap that covers a nozzle of the rocket motor. The end cap defines a baffled path through the end cap to dampen gas flow into the nozzle and prevent particles of the gun propellant from entering the rocket motor. A rocket motor may implement the rigid structure or the baffled end cap, or both structures.

A rocket motor for a gun-fired projectile is configured stiffen the burnable propellant in the rocket motor during burning and/or protect the rocket motor from the pressure that occurs during firing of the projectile from the gun. The rocket motor may include a rigid structure that is integrated into the burnable propellant grain to stabilize the burnable propellant grain during burning of the burnable propellant grain. The rigid structure has a matrix or truss-like shape that extends into the depth of the burnable propellant grain. The rocket motor may include a baffled end cap that covers a nozzle of the rocket motor. The end cap defines a baffled path through the end cap to dampen gas flow into the nozzle and prevent particles of the gun propellant from entering the rocket motor. A rocket motor may implement the rigid structure or the baffled end cap, or both structures.

A flare including: a casing; and a grain assembly, at least a portion of the grain assembly being slidably disposed in the casing, the grain assembly including: a shell structure; and a grain component at least partially disposed in the shell structure, the grain component including at least one combustible material and at least one reactive material positioned relative to the combustible material and configured to ignite combustion of the at least one combustible material; wherein the shell structure includes one or more fins at an aft end of the shell structure, the one or more fins being restrained into a first shape in the casing and configured to have a second shape, different from the first shape, when the restraint is removed.

A flare including: a casing; and a grain assembly, at least a portion of the grain assembly being slidably disposed in the casing, the grain assembly including: a shell structure; and a grain component at least partially disposed in the shell structure, the grain component including at least one combustible material and at least one reactive material positioned relative to the combustible material and configured to ignite combustion of the at least one combustible material; wherein the shell structure includes one or more fins at an aft end of the shell structure, the one or more fins being restrained into a first shape in the casing and configured to have a second shape, different from the first shape, when the restraint is removed.

A projectile apparatus is provided that includes a projectile, a propellant, and optional components such as a wading, a sabot, and an intermediary device. The projectile can be fired through a barrel having a smooth bore. A sabot is provided that can include molded features, for example, a base portion and a plurality of petal portions defining, in-part, a volume for accommodating a projectile. The sabot and wadding can include molded features that control and direct gases produced by the propellant. The apparatus can convert gas pressure or gas velocity into a high rate of projectile spin. The projectile has long-range accuracy due to a high or sustainable velocity and high rate of spin.

A projectile apparatus is provided that includes a projectile, a propellant, and optional components such as a wading, a sabot, and an intermediary device. The projectile can be fired through a barrel having a smooth bore. A sabot is provided that can include molded features, for example, a base portion and a plurality of petal portions defining, in-part, a volume for accommodating a projectile. The sabot and wadding can include molded features that control and direct gases produced by the propellant. The apparatus can convert gas pressure or gas velocity into a high rate of projectile spin. The projectile has long-range accuracy due to a high or sustainable velocity and high rate of spin.

A device for sealing a projectile guiding kit may be used with any kit having a rear unit and a front unit rotatably connectable to the rear unit thereof. The device may include an annular body adapted to envelope at least a front portion of the rear unit and at least a rear portion of the front unit of the kit. The device may include a flexible ring-shaped strip attached to an inner side and at a front end of the annular body and adapted to seal a gap between the rear unit and the front unit of the kit. The annular body may be adapted to slide towards the rear unit of the kit when subjected to a longitudinal acceleration that exceeds a predetermined acceleration value, thereby uncovering the gap and enabling uninterrupted rotation of the front unit with respect to the rear unit of the kit.

A receptacle in the body of a missile includes a plurality of electrical contacts connected to one or more electrically powered devices within the missile and configured to connect to an electrical power source. The receptacle receives a removable and reusable battery pack including connectors contacting the plurality of electrical contacts when the battery pack is mounted within the receptacle and one or more non-chemical, squibless batteries, preferably comprised of high power density primary cell lithium metal oxide cells. An interface circuit coupled to the squibless batteries initiates, terminates, and re-initiates delivery of electrical power from the squibless batteries to the plurality of electrical contacts based on a control input. Transportation, storage, and use risks associated with squibs in chemical batteries are avoided. During development testing, battery power may be shut down and restarted without the battery first becoming fully depleted and replaced shortening overall testing time and reducing expense.

A receptacle in the body of a missile includes a plurality of electrical contacts connected to one or more electrically powered devices within the missile and configured to connect to an electrical power source. The receptacle receives a removable and reusable battery pack including connectors contacting the plurality of electrical contacts when the battery pack is mounted within the receptacle and one or more non-chemical, squibless batteries, preferably comprised of high power density primary cell lithium metal oxide cells. An interface circuit coupled to the squibless batteries initiates, terminates, and re-initiates delivery of electrical power from the squibless batteries to the plurality of electrical contacts based on a control input. Transportation, storage, and use risks associated with squibs in chemical batteries are avoided. During development testing, battery power may be shut down and restarted without the battery first becoming fully depleted and replaced shortening overall testing time and reducing expense.